Three-piece solid golf ball

ABSTRACT

A three-piece solid golf ball comprising a center core, an intermediate layer, and a cover. The center core ( 1 ) has a diameter of at least 29 mm, a hardness in the range of 45-80 JIS C and a specific gravity of less than 1.4. The intermediate layer ( 2 ) has a thickness of at least 1 mm, a specific gravity of less than 1.2, and a hardness of at least 85 on JIS C scale. The cover ( 3 ) has a thickness of 1-3 mm and a hardness of 50-85 JIS C. The ball has a good total balance of properties in that feeling and controllability are improved at no sacrifice of flying performance and durability.

More than one reissue application has been filed. This reissueapplication is a continuation of Reissue application Ser. No.10/183,147, filed Jun. 28, 2002, which is a reissue of U.S. Pat. No.5,553,852, which issued on Sep. 10, 1996 from application Ser. No.08/271,953, filed Jul. 8, 1994; the disclosures of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to three-piece solid golf balls comprising acenter core, an intermediate layer, and a cover and more particularly,to three-piece solid golf balls which are improved in feeling on impact,controllability, and durability.

2. Prior Art

Among a variety of golf balls, thread-wound golf balls and solid golfballs are now popular. The solid golf balls are currently increasing tobe a mainstream product. Among them, two-piece solid golf ballsconsisting of a core and a cover are most widespread.

Most amateur golfers are fond of two-piece solid golf balls which haveexcellent flying performance and durability although these balls havethe disadvantages of a very hard feel on hitting and low control due torapid ball separation on hitting. For this reason, many of professionalgolfers and skilled amateur golfers who impose weight on feeling andcontrol prefer wound golf balls, especially wound golf balls using asoft balata cover, to two-piece solid golf balls. The wound golf ballsare superior in feeling and control, but inferior in flying distance anddurability to the two-piece solid golf balls.

Under the present situation that two-piece solid golf balls and woundgolf balls have contradictory characteristics as mentioned above,players make a choice of golf balls depending on their own skill andtaste.

In order to develop solid golf balls having a hitting feel approximateto the wound golf balls, two-piece solid golf balls of the soft typehave been considered. For such two-piece solid golf balls of the softtype, soft cores must be used. If the cores are soft, however, repulsionbecomes low with a concomitant loss of flying performance and durabilityis considerably deteriorated. That is, the superior flying performanceand durability which are a characteristic of two-piece solid golf ballsare lost, and in an extreme case, the balls become unacceptable forpractical use.

Controllability, which is required even on full shots with drivers, ismost important on control shots like approach shots. In an exemplarysituation that the next shot should fly beyond the bunker and a shortdistance from the green edge to the cup, the player who is eitherprofessional or amateur will naturally wish to hit a ball with a minimalrun. Such controllability of a golf ball largely depends on spinproperties.

On a full shot with a club having a relatively large loft, the club loftis dominant to that the ball itself so that almost all balls are givenan appropriate amount of spin and few balls overrun. However, on aapproach shot over a short distance of 30 or 50 yards, balls willsignificantly vary in run or controllability. The major factor causingsuch a difference is not a basic structure, but the identity of covermaterial. In two-piece solid golf balls, however, covers made of softmaterial are effective for improving controllability, but detrimentalfor gaining flying distance.

SUMMARY OF THE INVENTION

Therefore, an object of the present invention is to provide a solid golfball which is improved in feeling and controllability while maintainingthe superior flying performance and durability which are characteristicof solid golf balls, that is, improved in total balance.

In connection with a solid golf ball having a core forming the centerand a cover forming the outermost layer, the inventors have found thatby providing a relatively hard intermediate layer between the centercore and the cover, and controlling the size and specific gravity of thecore, intermediate layer and cover, the center core and core the covercan be made relatively soft to improve feeling and controllabilitywithout deteriorating flying performance and durability. The feeling andcontrollability can be improved in a favorable way.

Briefly stated, an intermediate layer having a thickness of at least 1mm, a specific gravity of less than 1.2, and a hardness of at least 85on JIS C scale is formed around a center core having a diameter of atleast 29 mm and a specific gravity of less than 1.4 and greater than theintermediate layer specific gravity. A cover having a thickness of 1 to3 mm is formed on the outer surface of the intermediate layer tocomplete a solid golf ball. Then even when the center core is softenedto a JIS C scale hardness of 45 to 80 and the cover softened to a JIS Cscale hardness of 50 to 85, the feeling and controllability can beimproved at no sacrifice of flying distance and durability. Further whenthe intermediate layer is formed of a resin composition based on a highrepulsion ionomer resin, the hitting feel and controllability can befurther improved with no sacrifice of flying distance and durability.

The present invention provides a three-piece solid golf ball comprisinga center core, an intermediate layer, and a cover wherein the centercore has a diameter of at least 29 mm and a specific gravity of lessthan 1.4, the intermediate layer has a thickness of at least 1 mm, aspecific gravity of less than 1.2, and a hardness of at least 85 on JISC scale. The cover has a thickness of 1 to 3 mm. The specific gravity ofthe intermediate layer is lower than the specific gravity of the centercore. In one preferred embodiment, the intermediate layer is formed of acomposition based on a high repulsion ionomer resin.

BRIEF DESCRIPTION OF THE DRAWING

The sole figure, FIG. 1 is a schematic cross section of a three-piecesolid golf ball according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is schematically illustrated a typicalthree-piece solid golf ball according to the invention. The ballincludes a spherical center core 1 forming the center of the ball and acover 3 forming the outermost layer of the ball. A relatively hardintermediate layer 2 is disposed between the core 1 and the cover 3. Thesize and specific gravity of the core 1, intermediate layer 2, and cover3 are set in specific ranges.

The center core has a diameter of at least 29 mm, preferably 29 to 37 mmand a specific gravity of less than 1.4, preferably 1.05 to 1.38. With adiameter of less than 29 mm, the intermediate layer must be relativelythick with losses of repulsion and feeling. With a specific gravity of1.4 or more, the ball has a heavier weight which exceeds the weightrequirement of golf balls.

On an impact entailing substantial deformation as found on driver shots,the player gets a feeling which largely depend on the hardness of thecenter core 1 and varies with the club head speed given by the player.Therefore, the hardness of the center core 1 should be set in accordancewith the head speed of the target players. In this sense, the centercore hardness is not particularly limited although it preferably rangesfrom 45 to 80, more preferably from 60 to 80 on JIS C scale (at thecenter core surface).

The center core 1 is generally formed from a well-known rubbercomposition comprising a base rubber, co-crosslinking agent and peroxidethrough heating, pressing and molding steps. The base rubber may be oneconventionally used in solid golf balls and preferably be selected frompolybutadiene rubber and mixtures of polybutadiene rubber andpolyisoprene rubber. Use of 1,4-polybutadiene rubber containing morethan 90% of cis structure is preferred for high repulsion. Theco-crosslinking agents used in conventional solid golf balls includezinc and magnesium salts of unsaturated fatty acids such as methacrylicacid and acrylic acid and esters of unsaturated fatty acids such astrimethylpropane trimethacrylate and they may be used in the presentinvention. Zinc acrylate is preferred for high repulsion. Theco-crosslinking agent is blended in amounts of about 15 to 30 parts byweight per 100 parts by weight of the base rubber. The peroxide may beselected from a variety of peroxides, preferably dicumyl peroxide andmixtures of dicumyl peroxide and1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane. The peroxide isblended in amounts of about 0.5 to 1 part by weight per 100 parts byweight of the base rubber. If desired, zinc oxide and barium sulfate maybe blended in the rubber composition for specific gravity adjustmentwhile antioxidants may also be blended.

The intermediate layer 2 has a radial thickness of at least 1 mm,preferably 1.5 to 3.5 mm, a specific gravity of less than 1.2,preferably 0.9 to 1 and lower than the center core specific gravity, anda hardness of at least 85, preferably 85 to 100 on JIS C scale. With athickness of less than 1 mm, repulsion is lowered to reduce flyingdistance. With a specific gravity of 1.2 or more, the center core musthave a relatively low specific gravity so that the golf ball may beincreased in inertia moment and reduced in spin property and thus losesome controllability. A similar detrimental effect is observed when theintermediate layer specific gravity is greater than the center corespecific gravity. A layer with a JIS C scale hardness of less than 85detracts from flying performance. The intermediate layer preferably hasan outer diameter of 38 to 41 mm though not limited thereto. Alsopreferably the difference in specific gravity between the center coreand the intermediate layer is 0.1 or more, especially 0.1 to 0.5 thoughnot limited thereto.

The intermediate layer 2 is effective in compensating for loweringrepulsion of the center core 1 which is made soft. It is then formed ofa relatively hard (JIS C scale hardness≧85), repulsive material.Although the material is not critical, preferred materials are ionomerresins, for example, Himilan 1706 and 1605 commercially available fromMitsui-dupont Polychemical K.K. and Surlyn commercially available fromE.I. dupont. A 1:1 blend of Himilan 1706 and Himilan 1605 is mostpreferred. In addition to the ionomer resin, the composition of whichthe intermediate layer is formed may further contain weight controlagents, for example, inorganic fillers such as zinc oxide and bariumsulfate, coloring agents such as titanium dioxide, and other additives.

The cover 3 has a radial thickness of 1 to 3 mm, preferably 1.5 to 2.5mm. A cover more than 3 mm thick is low in repulsion whereas a coverless than 1 mm thick is low in durability such as cut resistance.Although the hardness of the cover 3 is not particularly limited, it ispreferably set in a relatively soft range of 50 to 85, more preferably60 to 85 on JIS C scale because in this range, improvements in all ofrepulsion (flying performance), durability and controllability areexpected.

The cover 3 is generally formed of resinous materials which areconventionally used as the cover of solid golf balls, preferably thosematerials which are relatively soft (JIS C scale hardness 50 to 85) andhighly repulsive. Examples include ionomer resins such as Himilan 1650commercially available from Mitsui-dupont Polychemical K.K., Surlyn 8120commercially available from E.I. dupont, and mixtures thereof,thermoplastic polyester elastomers such as Hytrel 4047 commerciallyavailable from Toray-dupont K.K., and balata resins. If necessary,inorganic fillers may be blended in these resins for coloring purposes.

EXAMPLE

Examples of the present invention are given below by way of illustrationand not by way of limitation.

Examples and Comparative Examples

Using a center core, intermediate layer, and cover having thecomposition shown in Table 1, three-piece solid golf balls (Examples1-6, Comparative Examples 1-3) were prepared. The center core wasprepared by kneading the respective components in a roll mill andpressure molding at 155° C. for 15 minutes. The intermediate layer wasformed by injection molding so as to enclose the outer surface of thecenter core. The cover was formed around the intermediate layer byinjection molding. The three-piece solid golf balls were completed inthis way. The parameters associated with the core, intermediate layerand cover are shown in Table 2.

The golf balls were evaluated for spin characteristic, flyingperformance, feeling, and durability by the following tests. The resultsare shown in Table 2.

Spin Characteristic

Using a swing robot manufactured by True Temper Co., the ball was hit bythe driver at a head speed of 45 m/s (abbreviated as W1 HS45 in Table 2)and by the sand wedge at a head speed of 17.6 m/s (abbreviated as SWHS17.6 in Table 2). The ball spin (rpm) was observed using a science eye(manufactured by Bridgestone Corporation).

Feeling

Professional golfers evaluated a feeling on impact according to thefollowing criterion.

-   -   ◯: good    -   Δ: average    -   ×: poor

Flying Performance

In the spin and feeling tests, the flying distance the ball traveled wasalso measured. Total evaluation was made according to the followingcriterion.

-   -   ◯: good    -   Δ: average    -   ×: poor

Durability

Using a flywheel hitting machine, the ball was repeatedly hit at a headspeed of 38 m/s until the ball was broken. With the number of hitscounted, the ball was rated according to the following criterion.

-   -   ◯: good    -   Δ: average    -   ×: poor

TABLE 1 Example Comparative Example 1 2 3 4 5 6 1 2 3 Center coreCis-1,4-polybutadiene 100 100 100 100 100 100 100 100 100 Zinc acrylate20 20 20 30 20 20 20 25 20 Zinc oxide 56 36 36 20 23 10 90 2.5 55Antioxidant 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 Dicumyl peroxide 0.650.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 Intermediate layer Himilan 170650 50 50 50 50 50 50 50 50 Himilan 1605 50 50 50 50 50 50 50 50 50 CoverHimilan 1650 50 50 50 50 50 50 Surlyn 8120 50 50 50 50 50 50 Hytrel 4047100 100 Trans-isoprene rubber 90 Natural rubber 10 Note: The amounts ofcomponents blended are parts by weight and their proportion isindependent among the center core, intermediate layer, and cover.

TABLE 2 Example Comparative Example 1 2 3 4 5 6 1 2 3 Center core Outerdiameter, mm 31.52 35.28 35.28 35.28 35.29 36.40 27.68 35.24 31.52Hardness, JIS C 66 66 66 79 66 66 66 73 66 Specific gravity 1.36 1.241.24 1.19 1.16 1.07 1.56 1.19 1.35 Intermediate layer Thickness, mm 3.41.7 2.2 2.2 1.7 2.0 5.7 1.8 1.6 Hardness, JIS C 91 91 91 91 91 91 91 8291 Specific gravity 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.97 0.95 Outerdiameter, mm 38.35 38.73 39.65 39.66 38.73 40.40 39.00 38.91 34.56 CoverThickness, mm 2.2 2.0 1.5 1.5 2.0 1.8 1.8 1.9 4.0 Specific gravity 0.970.97 0.97 1.10 1.13 0.97 0.97 1.10 0.97 Hardness, JIS C 82 82 82 61 7882 82 61 82 Ball Outer diameter, mm 42.68 42.67 42.67 42.70 42.70 44.0042.65 42.63 42.65 Weight, g 45.50 45.45 45.50 45.55 45.53 45.60 45.5045.55 45.50 Performance Spin (rpm) W1 HS45 3300 3020 3030 3920 3600 303035 3600 3250 SW HS17.6 3900 4000 4300 6390 5800 4100 4100 4050 3500Feeling Δ ◯ ◯ Δ ◯ ◯ X ◯ ◯ Flying performance ◯ ◯ ◯ ◯ Δ ◯ X X XDurability ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯

As is evident from Table 2, the three-piece solid golf balls of thepresent invention have a good balance of properties in that the centercore and cover can be made soft to ensure a pleasant feeling andcontrollability (spin) without deteriorating flying performance anddurability.

There has been described a three-piece solid golf ball which includes acore, intermediate layer and cover having controlled size, hardness andspecific gravity so that the ball has a good total balance of propertiesin that a relatively soft center core and cover are used to ensure apleasant feeling and controllability at no sacrifice of flyingperformance and durability.

Japanese Patent Application No. 5-193065 is incorporated herein byreference.

Although one preferred embodiment have been described, manymodifications and variations may be made thereto in the light of theabove teachings. It is therefore to be understood that within the scopeof the appended claims, the invention may be practiced otherwise than asspecifically described.

1. A three-piece solid golf ball comprising; a center core, anintermediate layer, and a cover enclosing the core through theintermediate layer, said center core having a diameter of at least 29 mmand a specific gravity of less than 1.4, said intermediate layer havinga thickness of at least 1 mm, a specific gravity of less than 1.2, and ahardness of at least 85 on JIS C scale, the specific gravity of saidintermediate layer being lower than the specific gravity of said centercore, and said cover having a thickness of 1 to 3 mm and being softerthan said intermediate layer.
 2. The golf ball of claim 1 wherein saidintermediate layer is formed of a high repulsion ionomer resin basecomposition.
 3. The golf ball of claim 1 wherein said center core has ahardness of 45 to 80 on JIS C scale and said cover has a hardness of 50to 85 on JIS C scale.
 4. The golf ball of claim 1 wherein said centercore is comprised of a polybutadiene base rubber composition.
 5. Thegolf ball of claim 1 wherein the diameter of said center core is in therange of 29-37 mm.
 6. The golf ball of claim 1 wherein a difference inthe specific gravity between the center core and the intermediate layeris in the range of 0.1 to 0.5.
 7. The golf ball of claim 1 wherein thespecific gravity of said intermediate layer is in the range of 0.9 to1.0.
 8. The golf ball of claim 1 wherein the hardness of saidintermediate layer is in the range of 85-100 on JIS C.
 9. A three-piecesolid golf ball, comprising: a center core, an intermediate layer, and acover enclosing said center core through the intermediate layer; saidcenter core having a diameter of at least 29 mm and a specific gravityof less than 1.4; said intermediate layer formed of an ionomer resin andhaving a thickness of at least 1 mm, a specific gravity of less than1.2, and a hardness of at least 85 on JIS C scale, the specific gravityof said intermediate layer being lower than the specific gravity of saidcenter core; and said cover having a thickness of 1 to 3 mm and beingsofter than said intermediate layer; and wherein said cover comprisesthermoplastic polyester.